Plastic Injection Molding 101

Plastic injection molding isn’t a one-size-fits-all process – and that’s part of what makes it so versatile. Depending on the type of part you’re making, different molding techniques can be used to achieve specific results in look, feel, and function.

Standard Molding

This is the classic approach – using a single color and material to create a part. It’s the go-to method for producing everyday items like beverage containers, bottle caps, auto components, and toys. Simple, efficient, and highly reliable.

Overmoulding

Overmoulding takes things a step further. It’s a two-stage process used when a product needs multiple materials – for example, a handle with a soft, rubber-like grip molded over a rigid plastic base. First, the main (or substrate) part is made. Then it’s placed into another mold, where a second thermoplastic is molded over it. The two materials form a strong mechanical or chemical bond, creating a more durable and ergonomic part.

Insert Molding

In insert molding, an existing component – often made from a different material like metal – is placed into the mold before the plastic is injected around it. Think of knobs, dials, or fasteners with metal cores and plastic exteriors. This technique combines the strength of metal with the versatility of plastic, all in one seamless piece.

Read more about overmoulding and insert molding.

Two-Shot (Dual-Shot) Molding

Two-shot molding is another multi-material process, but it’s done entirely within a single machine – no transferring parts between molds. The first shot creates the base layer, and then a second injection adds another color or type of plastic. This method is perfect for products like power tool housings, where you might want a durable body with a contrasting, branded-color handle. The two layers bond either chemically or mechanically, resulting in a high-quality, fully integrated part.

Read more about multi-shot injection molding. 

In short, each of these molding methods brings its own strengths – and choosing the right one depends on the design, function, and performance goals of your part.

Selecting the right molding technique is only part of the process – the material itself is equally important. When it comes to injection molding, there’s a wide range of plastic materials to consider. From common polymers to specialized blends, hundreds of resins are available – each with its own characteristics, processing requirements, and performance profiles. Even within a single plastic type, different grades are designed for specific applications. 

The 10 most common injection molding plastic types:

• Acrylic (PMMA) – known for its clarity and scratch resistance
• Acrylonitrile Butadiene Styrene (ABS) – tough, durable, and easy to mold
• Nylon (Polyamide, PA) – strong and wear-resistant, great for mechanical parts
• Polycarbonate (PC) – tough and impact-resistant
• Polyethylene (PE) – flexible and versatile, used in everything from containers to tubing
• Polyoxymethylene (POM) – also called acetal, great for precision parts and smooth movement
• Polypropylene (PP) – lightweight, chemical-resistant, popular across industries
• Polystyrene (PS) – affordable and easy to process, often used in packaging and disposables
• Thermoplastic Elastomer (TPE) – rubber-like flexibility with the processability of plastic
• Thermoplastic Polyurethane (TPU) – elastic, abrasion-resistant, and perfect for flexible parts

What is the Hardest Plastic For Injection Molding?

If we’re talking about sheer strength and durability, Polycarbonate (PC) is one of the toughest out there. It’s impact-resistant, transparent, and versatile – often used in safety gear, electronics, and engineering components. Close behind are Nylon (Polyamide), known for its strength and resistance to wear and chemicals, and Acetal (POM), valued for its stiffness and ability to handle stress without deforming. In the end, the “best” plastic really depends on your part’s purpose – whether it needs to flex, shine, endure, or simply last.

An injection molding machine consists of a material hopper, barrel, injection ram or rotating screw, heating system, movable mold components, ejectors, and the mold itself within the mold cavity. Most machines operate horizontally.

The clamping unit is what opens and closes the mold and pushes out finished parts. There are two main types: the toggle type, which uses a mechanical linkage, and the straight-hydraulic type, where a hydraulic cylinder moves the mold directly.

Plastic is fed into the hopper at one end of the barrel, and the screw inside rotates, driven by an electric motor, to melt the plastic. Once enough molten plastic has built up, it’s injected into the mold attached to the other end. During this process, the machine carefully controls the speed of the screw and the injection pressure to make sure the mold fills correctly. The settings are based on specific screw positions and pressure targets, ensuring consistent results part after part.

The mold itself is just as important as the machine. It’s made from high-strength metal and usually consists of two halves: a cavity side and a core side. Molten plastic enters the mold through a sprue and flows into the cavities via runners and gates. After cooling, the mold opens, and ejector rods push the finished parts out.

Even though molds may look simple from the outside, they are full of precision features – often machined to tolerances of less than 0.001 inches (0.025 mm), about a third of the thickness of a piece of paper. Every component needs to work perfectly to produce accurate, high-quality parts.

With the materials selected and the mold prepared, the process of turning raw plastic into finished parts can begin. The plastic injection molding process is surprisingly fast – most cycles take anywhere from six seconds to a couple of minutes. Here’s a closer look at what happens during a typical cycle:

Clamping: Before any plastic is injected, the two halves of the mold need to be securely closed. The clamping unit does this, applying significant force to keep the mold shut while the plastic is injected. How long this takes depends on the machine – bigger machines with larger molds naturally take a bit more time to close.

Injection: Plastic usually enters the machine as small pellets. These pellets are fed into the injection unit, where the rotating screw pushes them through heated zones in the barrel. As the plastic melts, it’s prepared in an exact amount called a shot – enough to form the finished part. Once the mold is clamped, the machine injects this molten plastic into the mold. The injection speed depends on factors like shot size, pressure, and the part’s design.

Cooling: As soon as the molten plastic hits the inside of the mold, it begins to cool and harden, taking on its final shape. Some shrinkage is normal during this stage. The mold can’t be opened until the part has cooled sufficiently, which depends on the plastic’s properties, the thickness of the part, and the desired dimensions. Review Rosti’s material shrink rate guide.

Ejection: Finally, once the part has cooled, the machine’s ejection system pushes it out of the mold. At the same time, a new shot of plastic is ready to go, so the cycle can start again without delay.

Get a look at how plastic injection molding works, showing the basic steps from melting plastic to shaping it in a mold.

After an injection molding cycle, the work isn’t always done – many parts go through post-processing to get them ready for use. These steps can be functional, like adding strength, or decorative, like branding or color. Here are six common post-processing techniques used with injection molded parts:

• Gate Trimming – removing excess plastic left where the material entered the mold
• Painting – adding color or surface finishes for appearance or protection
• Laser Marking – etching logos, serial numbers, or other information directly onto the part
• Pad Printing – transferring detailed graphics or text onto the surface
• Heat Staking – joining parts together using heat to soften and bond the plastic
• Ultrasonic Welding – fusing plastic components using ultrasonic vibrations

Each of these steps helps turn a molded piece into a finished part that’s ready for its intended purpose.

The lifespan of a plastic injection mold can range from a few hundred to over a million cycles, depending on how it’s built, maintained, and used. Factors like the operating environment, materials, maintenance routines, molding conditions, and overall mold design all play a role in how long a mold lasts.

Regular inspections, proper maintenance, protective coatings, and operating the mold within recommended conditions can significantly extend its lifespan. Following SPI mold classifications also helps ensure durability and consistent performance. It’s important to watch for defects such as sink marks, surface delamination, flow lines, burn marks, or flashing – these can either cause damage to the mold or signal that wear and tear is already occurring.

Injection molding is a great way to produce large quantities of identical parts quickly, but it’s not as simple as it looks. Even small mistakes early in product development can lead to serious defects, affecting the quality, durability, and cost of your parts. Problems can come from design flaws, production errors, or gaps in quality control. That’s why staying proactive and addressing potential risks from the very beginning is key to keeping the process smooth and ensuring the final product performs as intended.

Below are seven of the most common defects in plastic injection molding and strategies to prevent them:

1. Flow Lines

Flow lines are visible streaks or patterns on a part’s surface caused by molten plastic moving at different speeds and solidifying unevenly.

Causes:

• Low injection speed or pressure
• Varying wall thickness in the mold

Prevention:

• Maintain consistent wall thickness
• Use chamfers and fillets of appropriate length
• Place the gate in thinner sections of the mold

2. Sink Marks

Depressions, dents, or craters that form in thick sections due to uneven cooling and shrinkage.

Causes:

• Thicker walls cooling slower than outer sections
• Inadequate pressure in the mold
• High temperatures at the gate

Prevention:

• Reduce the thickness of thick sections for more uniform cooling
• Allow more time for cooling
• Design with proper rib and wall thickness

3. Surface Delamination

The surface separates into thin layers that can peel away.

Causes:

• Contaminants in the material
• Excessive use of mold release agents

Prevention:

• Pre-dry the plastic before molding
• Increase mold temperature
• Minimize reliance on mold-release agents

4. Weld Lines (Knit Lines)

Lines where two flows of molten plastic meet but fail to bond properly, reducing part strength.

Causes:

• Flow wrapping around holes or obstacles in the mold
• Incorrect resin temperature

Prevention:

• Raise resin temperature
• Increase injection speed and pressure
• Use lower viscosity materials
• Redesign molds to remove unnecessary partitions

5. Short Shots

Incomplete filling of the mold, resulting in unusable parts.

Causes:

• Restricted flow due to narrow gates, blockages, or trapped air
• Insufficient injection pressure
• Material viscosity or low mold temperature

Prevention:

• Increase mold temperature
• Improve venting to allow air to escape
• Adjust gate design

6. Warping

Twists or bends caused by uneven shrinkage during cooling.

Causes:

• Non-uniform mold cooling
• Uneven wall thickness
• Semi-crystalline materials are more prone to warping

Prevention:

• Allow gradual, uniform cooling
• Maintain consistent wall thickness throughout the part
• Ensure mold design promotes unidirectional flow

7. Jetting

Squiggly flow patterns caused when molten plastic begins solidifying before the cavity is filled.

Causes:

• High injection pressure
• Premature solidification in the mold

Prevention:

• Reduce injection pressure for smoother fills
• Increase mold and resin temperature
• Position the gate along the shortest flow path

Equally important are the broader risks associated with plastic injection molding – from worker safety to environmental impact – which must be managed to ensure a responsible and efficient manufacturing process. Understanding these risks and taking proper precautions is essential for keeping workers safe and minimizing the impact on the environment.

Toxic Fumes: Heating plastic during injection molding can release chemicals like styrene, benzene, and formaldehyde, which may affect breathing or even lead to long-term health issues. Good ventilation and protective gear, like respirators, are essential to keep exposure to a minimum.

Burns and Injuries: Working with molten plastic and running injection molding machines comes with the risk of burns and other injuries. Proper training and protective equipment – gloves, goggles, and heat-resistant clothing – are crucial for staying safe on the job.

Environmental Impact: Injection molding isn’t without its environmental footprint. It can generate plastic waste, contribute to pollution, and deplete resources. 

Shaping a Sustainable Future with Rosti

As a plastic molding company and contract manufacturer, Rosti sits at the heart of the supply chain, with both the responsibility and opportunity to drive positive environmental impact. Our design-for-manufacturing processes influence product design, material choices, and waste management across the entire supply chain. That’s why sustainability is central to our business strategy, guiding every decision we make. By working closely with our customers and partners, we aim to promote sustainable manufacturing and help shape a greener future for the plastics industry.

Read more about our sustainability strategy.

Plastic injection molding is incredibly versatile, making it a go-to choice for producing a wide range of parts and products. Its advantages go beyond just getting the job done – it offers real benefits that can impact cost, performance, and design.

Speed and cost-effectiveness: The process is simple, highly automatable, and efficient. That means faster production times, lower costs, and the potential for greater revenue.

Lightweight: Plastic is strong yet much lighter than metal or other traditional materials. That’s why many manufacturers consider switching from metal to plastic parts – it can improve performance and reduce weight without sacrificing strength.

Is metal to plastic conversion a process that could benefit your product? Get our comprehensive guide here.

Superior quality: Injection molding consistently produces precise, uniform parts. Its dimensional accuracy is hard to beat, and data-driven tools like Mould Flow for design validation, RJG eDart process controls, and robotics help maintain top-notch quality.

Design flexibility: Whether your part is simple or highly complex, injection molding works. It integrates easily with CAD and CAM systems, making it possible to hit exact specifications and create intricate details with ease.

Customizable colors and traits: You can achieve virtually any color or visual effect. With over 15,000 types of plastics available, it’s easy to tailor parts for strength, UV resistance, or other performance requirements.

Compliance: If your product needs to meet FDA, NSF, REACH, or RoHS standards, there are resins available that comply.

Sustainability: The process generates minimal waste, and leftover material can often be recycled, making it a more environmentally conscious choice compared to other manufacturing methods.

Injection molding isn’t just about making parts – it’s about making parts that meet your needs efficiently, reliably, and with plenty of room for customization.

For OEMs across industries, plastic parts are an essential and cost-effective option. Plastic injection molding is a versatile process that can reduce part weight by up to 50%, create complex shapes, and produce less scrap – all while keeping costs down. It’s used in everything from medical devices to automotive components, appliances, and more.

Automotive: Plastic parts like bumpers, dashboards, and cup holders are lightweight, durable, heat- and weather-resistant, and help reduce noise and vibration.

Medical: Plastics offer precision and reliability for devices and components, with high tensile strength, heat resistance, and flexibility in design, size, and color. 

Read more about Rosti’s medical solutions. 

Construction: Injection molded tools, fasteners, and accessories are cost-effective, durable, lightweight, and stable even in harsh environments.

Plumbing: Plastic pipes and fittings resist corrosion, conduct less heat, are chemically stable, and offer lower cost and weight compared to traditional materials.

Appliances: Parts such as gears, shelves, and trays benefit from plastics’ durability, heat and chemical resistance, reduced weight, and design flexibility.

Electronics: Plastic components improve insulation, handle high voltages and temperatures, reduce weight, and allow for more complex designs.

Whenever repeatability, consistency, affordability, and reliability are critical for medium- to high-volume parts, injection molding is a smart choice. It offers both functional and design advantages across countless industries.

The story of plastic injection molding goes back to 1868, when John W. Hyatt invented a way to make celluloid, originally to replace ivory in billiard balls. Just a few years later, in 1872, Hyatt and his brother Isaiah created the first injection molding machine. It used a simple plunger to push celluloid through a heated cylinder into a mold – paving the way for mass-produced items like buttons, combs, and more.

By the early 1900s, safer cellulose-based plastics were developed, and before World War II, materials like polystyrene and PVC became widely used. After the war, the growing demand for affordable, mass-produced parts helped cement injection molding as a cornerstone of the plastics industry.

A big leap came in 1946 when James Watson Hendry introduced a screw-based injection machine, giving manufacturers much better control and higher-quality parts.

Just like many other industries, the world of plastics is continuously changing and growing. Companies are continually investing in automation to improve productivity and increase capacity and efficiency.

Plastic injection molding services are fast, efficient, and precise when conducted by experienced technicians utilizing advanced automated machinery. Automation helps ensure each manufactured component will be identical to the validated design.

Taking automation a step further, lights-out manufacturing involves processes, innovative machinery, and technology installed within facilities. These systems can perform tasks that would normally require constant oversight by on-site technicians. Essentially, an automated production facility can run “lights-out” – or without substantial assistance from human labor, lights, heat, and other costly factors for a business. However, most highly automated facilities still require the supervision of highly skilled laborers and technicians. Lights-out manufacturing processes allow companies to keep facilities running 24 hours a day, seven days a week, with a scaled-back workforce or virtual technician oversight.

Lights-Out Manufacturing

Rosti’s Bunsen Drive facility ensures the maximum amount of efficiency out of every square foot of space. Since the opening of the Bunsen facility, the United States Government issued Rosti a patent to validate the processes that take place within the facility. Every detail from the lighting to the part conveyance system has been meticulously planned. This attention to the little nuances of a manufacturing plant is what separates this facility from others in the world. 

Additionally, infrastructure expansions have set the stage for the additional production presses that have already been added, and more that will come in the future.

The advancements in automation and “lights-out” manufacturing processes have impacted the plastics industry at a high level. It allowed businesses to improve in the areas of cost and turn-around time. It has also allowed plastic part producers to lower the likelihood of defects and increase the overall quality of products created.

Learn about Rosti’s scientific molding practices in our complete guide to scientific molding.

Five critical ways lights-out manufacturing has transformed injection molding include:

1. It has helped U.S. manufacturers gain a globally competitive advantage.
2. It allows large orders to be completed quickly without the higher costs associated with running additional shifts.
3. It provides a greater ability to meet quality control, delivery, and cost containment requirements.
4. It requires a highly trained and dedicated workforce to manage and maintain state-of-the-art automation equipment and processes.
5. It creates an added level of protection for intellectual property.